Weatherproof decorator cover with positive indicator

ABSTRACT

A weatherproof switch cover includes a base plate, a rocker arm provided in the base plate and movable between a first position and a second position and a membrane provided below the rocker arm, the membrane providing a weatherproof seal.

CROSS REFERENCE TO RELATED APPLICATIONS

The present disclosure is based on and claims benefit from U.S.Provisional Application Ser. No. 62/249,994 filed Nov. 3, 2015 entitled“Weatherproof Decorator Cover with Positive Indicator” the entirecontents of which are herein incorporated by reference.

BACKGROUND

Field

The present disclosure relates to switch covers and, more particularly,to weatherproof decorator switch covers with positive indicators.

Description of the Related Art

Weatherproof toggle switches are often used in damp or wet environments.Various ways exist for providing a weatherproof toggle switch. One wayis to provide a switch designed and manufactured to include a sealedconfiguration for preventing condensation or water from entering theswitch. Another way is to provide a weatherproof switch plate coverwhich includes a sealed membrane that covers the forwardly projectingtoggle lever. When used in conjunction with the weatherproof switchplate cover, a standard interior toggle switch can be used in damp orwet environments.

Interior wall switches have evolved from simple on/off toggle switchesto more attractive décor type switches. Décor type switches includedecorator rocker style switches.

Weatherproof switch plate covers exist for use with rocker styleswitches. However, these covers generally consist of a flat rubbermembrane that covers the entire switch. One downside of these covers isthat it is not possible to visually determine whether the switch is inthe on or off position.

SUMMARY

A weatherproof cover includes a base plate, a rocker arm provided in thebase plate and movable between a first position and a second positionand a membrane provided below the rocker arm, the membrane providing aweatherproof seal.

A weatherproof cover kit includes a rocker switch adapted for switchingelectrical power on and off, a weatherproof electrical box in which therocker switch is to be mounted and a weatherproof switch cover adaptedfor covering the rocker switch and mountable to the weatherproofelectrical box. The weatherproof switch cover includes a base plate, arocker arm provided in the base plate and movable between a firstposition and a second position, and a membrane provided below the rockerarm, the membrane providing a weatherproof seal.

A multi-gang weatherproof cover includes a base plate, at least tworocker arms provided in the base plate, each rocker arm movable betweena first position and a second position and a membrane provided below theat least two rocker arms, the membrane providing a weatherproof seal.

A multi-gang weatherproof cover includes a base plate, a rocker armprovided in the base plate and movable between a first position and asecond position, a flip cover pivotally mounted to the base plate andproviding a weatherproof seal and a membrane provided below the rockerarm, the membrane providing a weatherproof seal.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present disclosure and many of theattendant advantages thereof will be readily obtained as the samebecomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

FIG. 1 is a top perspective view of a representative weatherproof switchcover according to an illustrative embodiment of the present disclosure;

FIG. 2 is a bottom perspective view of the representative weatherproofswitch cover according to an illustrative embodiment of the presentdisclosure;

FIG. 3 is side perspective view of a representative weatherproof switchcover according to an illustrative embodiment of the present disclosureand a utility box housing a decorator type rocker style switch;

FIG. 4 is an exploded view of a weatherproof switch cover according toan illustrative embodiment of the present disclosure;

FIGS. 5A and 5B are cross-sectional side views showing how theweatherproof switch cover interacts with a decorator type rocker styleswitch according to an illustrative embodiment of the presentdisclosure;

FIG. 6 is a perspective view of a multi-gang weatherproof switch coverfor covering two decorator type rocker style switches according to anillustrative embodiment of the present disclosure;

FIG. 7 is a perspective view of a multi-gang weatherproof switch coverfor covering a decorator type rocker style switch and a duplex outletaccording to an illustrative embodiment of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present disclosure may be provided asimprovements to weatherproof switch covers. For example, a weatherproofswitch cover according to an embodiment of the present disclosure allowsan decorator type rocker switch to be used in wet or damp environments.

Illustrative embodiments of the present disclosure provide multi-gangweatherproof covers for covering two or more decorator type rockerswitches and/or a decorator type rocket switch and a duplex outlet.

According to an embodiment of the present disclosure, a weatherproofswitch cover includes a rocker switch mechanism that provides positivetactile feedback to a user when the user moves the switch between the onand off positions.

In certain illustrative embodiments described herein, one or morecomponents of the weatherproof switch cover may be constructed frommetal (e.g., stamped steel, spring steel), plastic (e.g., polycarbonateor nylon) or a combination of such materials. Alternatively, steel,galvanized steel, brass, aluminum or other appropriate alloy may be usedfor the appropriate components. Of course, other types of materials suchas other types of plastics, composites, etc. may be used as desired andwhere appropriate.

In certain embodiments of the present disclosure, a weatherproof switchcover as disclosed herein is mounted to a weatherproof electrical box inwhich a decorator type rocker switch is provided. The weatherproofelectrical box may be a multi-gang box for housing one or more decoratortype rocker switches and/or one or more duplex outlets. The weatherproofswitch cover as disclosed herein may include one or more rocker armassemblies for covering one or more decorator type rocker switchesand/or one or more weatherproof flip covers for covering one or morestandard or decorator type duplex outlets.

A representative weatherproof switch cover according to an embodiment ofthe present disclosure is shown in FIGS. 1 and 2 and is referred togenerally as switch cover 100. According to this embodiment of thepresent disclosure, switch cover 100 includes a weatherproof rocker armassembly including a rocker arm 30 mounted to a base plate 10. The baseplate 10 includes a top wall 10 a, a bottom wall 10 b, a pair of sidewalls 10 c and 10 d and an exterior surface 10 e secured to orintegrally molded into the walls. The space within the walls 10 a-10 dand the exterior surface 10 e is an open interior area 10 f. A gasket 90may be removably provided on a back surface of the exterior surface 10 eof base plate 10 as will be described later below. Screws 24 extendthrough holes 12 provided in spacers 14 formed along the upper and lowerends of the base plate 10 such that the screws 24 align with screw holesin a yoke 130 of an electrical device, such as a decorator type rockerstyle switch 120, as will be described later below. A retainer 80 issecured to base plate 10 using fasteners 15. Retainer 80 holdscomponents of the rocker arm assembly in place. A sealing membrane 70which includes recessed nubs 72A, 72B provides a weatherproof seal aswill be described later below.

FIG. 3 depicts a single gang weatherproof electrical box 20 which may bemade of metal, plastic, etc. A decorator type rocker style switch 120 ispositioned in weatherproof electrical box 20 as shown. Electrical wiring(not shown) is run into electrical box 20 via one or more knockouts 121and is connected to decorator type rocker style switch 120 in the usualmanner. Decorator type rocker style switch 120 includes a rocker arm122. Generally, switch 120 is arranged such that rocker arm 122 ismovable between an “ON” position and an “OFF” position, where theposition shown is the “OFF” position. Rocker arm 122 would normally bepressed in area A in order to move rocker arm 122 to the “ON” position.Baseplate 10 of a weatherproof switch cover 100 according to anembodiment of the present disclosure, is positioned over rocker styleswitch 120 and is secured to weatherproof electrical box 20 such thatgasket 90 provides a weatherproof seal between baseplate 10 and an outeredge of weatherproof electrical box 20. Screws 24 which extend throughholes 12 in base plate 10 are aligned with screw holes 132 in the yoke130 of the decorator type rocker style switch 120 for securing baseplate 10 to weatherproof electrical box 20. As will be described in moredetail below, when weatherproof switch cover 100 is mounted toelectrical box 20, pressing rocker arm 30 in area A′ will cause switch120 to move to the “ON” position.

An exploded view of switch cover 100 is shown in FIG. 4. A weatherproofrocker arm assembly according to an embodiment of the present disclosureincludes rocker arm 30, plunger assembly 40, flipper 50, chassis 60,sealing membrane 70 and retainer 80. The rocker arm assembly is mountedto baseplate 10. As will be described later below with respect to FIG.5, flipper element 50 cooperates with the plunger assembly 40 forproviding a snap like action so that the user can feel the switchswitching thus providing tactile feedback to the user. Retainer 80 issecured to the back of base plate 10 to keep the rocker arm assemblytogether as described above. Sealing membrane 70 and gasket 90 may bemade of any suitable weatherproof sealing material including, forexample, rubber, neoprene, etc. The spring 42, finger 44, seen in FIG.5A, and flipper 50 may be made of suitable material such as steelincluding, for example, spring steel, etc. The other elements of switchcover 100 may be made from metal (e.g., stamped steel), plastic (e.g.,polycarbonate or nylon) or a combination of such materials. If the baseplate 10 and/or retainer 80 are made of metal, the retainer 80 may besecured to the base plate 10 with fasteners 15, seen in FIG. 2, whichmay include rivets, screws, a press fit, etc. If the base plate 10and/or retainer 80 are made of plastic, fasteners 15 may include sonicwelds, screws, rivets, etc. Rubber o-rings 22 slip onto screws 24 andprovide a weatherproof seal around orifices 12 in base plate 10.

A weatherproof switch cover 100 according to an embodiment of thepresent disclosure is shown in cross-section in FIGS. 5A and 5B mountedto a utility box 20. Rocker arm 122 is representative of a rocker arm ofa decorator type rocker style switch 120 that is mounted to box 20 belowweatherproof switch cover 100. For ease of description, the otherportions of switch 120 are not shown. Rocker arm 30 includes fingers32A, 32B located adjacent sealing membrane 70. Sealing membrane 70includes recessed nubs 72A, 72B. When rocker arm 30 is pressed alongsection B, rocker arm 30 moves into the position shown in FIG. 5A. Inthis position, finger 32B urges nub 72B into the rocker switch 122 belowsuch that the rocker switch below will be in, for example, the “OFF”position. When rocker arm 30 is pressed along section A, finger 32Aurges nub 72A into the rocker switch 122 below such that the rockerswitch 122 moves into, for example, the “ON” position shown in FIG. 5B.

Sealing membrane 70 includes a multi-tiered edge 74. Sealing membrane 70is sandwiched between carriage chassis 60 and retainer 80 such thatretainer 80 presses multi-tiered edge 74 into a correspondingly shapededge of carriage chassis 60, thus providing a weatherproof seal.

Flipper 50 rests on rocker nub 62 provided on carriage chassis 60.Spring 42 and finger 44 are movably provided in a recess 35 formed onthe back of rocker arm 30. Spring 42 urges finger 44 against flipper 50just above nub 62. As shown in FIG. 5A, flipper 50 is in a firstposition. When rocker arm 30 is pressed along section A, finger 44 movessuch that flipper 50 cams over in the opposite direction into the secondposition as shown in FIG. 5B. This arrangement provides a positivetactile feel when rocker arm 30 is moved between the “ON” and “OFF”positions.

FIG. 6 depicts a duplex weatherproof switch cover 200 according to anembodiment of the present disclosure. According to this embodiment, baseplate 202 is dimensioned to cover a 2 gang box 204 housing two decoratortype rocker switches 206, 208 as shown. A gasket 214 is provided betweenbase plate 202 and box 204. One or more weatherproof rocker armassemblies including rocker arms 210 and 212 are mounted to base plate202. According to an embodiment of the present disclosure, the rockerarm assemblies are similar to the rocker arm assembly (e.g., singleswitch) described above with respect to FIG. 4. Of course, instead ofproviding separate rocker arm assemblies, the components of the rockerarm assembly may be designed and dimensioned for use with the 2 gangweatherproof switch cover 200. Screws 220 align with corresponding holes232 in the yoke 230 of the decorator type rocker style switches 206,208.

FIG. 7 depicts a duplex weatherproof switch/outlet cover 300 accordingto an embodiment of the present disclosure. According to thisembodiment, base plate 302 is dimensioned to cover a 2 gang box 304housing a decorator type rocker switch 306 and a duplex outlet 308,e.g., a decorator type duplex outlet, as shown. A gasket 314 is providedbetween base plate 302 and box 304. A weatherproof rocker arm assemblyincluding rocker arm 310 is mounted to base plate 302. The rocker armassembly is similar to that described above with respect to FIG. 4.According to this embodiment, a flip cover 312 is pivotally mounted tobase plate 302 via a spring biased hinge 332 and provides access toduplex outlet 308. Flip cover 312 includes a gasket 330 providing aweatherproof seal. Screws 320 align with corresponding holes 332 in theyoke 330 of the decorator type rocker style switches 306 and the duplexoutlet 308.

As shown throughout the drawings, like reference numerals designate likeor corresponding parts. While illustrative embodiments of the presentdisclosure have been described and illustrated above, it should beunderstood that these are exemplary of the disclosure and are not to beconsidered as limiting. Additions, deletions, substitutions, and othermodifications can be made without departing from the spirit or scope ofthe present disclosure. Accordingly, the present disclosure is not to beconsidered as limited by the foregoing description.

What is claimed is:
 1. A weatherproof switch cover comprising: a baseplate including top and bottom walls, a pair of side walls, an exteriorsurface and an open interior area, the exterior surface being secured toor integrally molded into the top and bottom walls and the pair of sidewalls, the exterior surface having a rectangular opening configured toalign with a decorator electrical switch and at least one hole forattaching the base plate to a yoke of the decorator electrical switch; arocker arm operatively coupled to the base plate within the openinterior area and extending at least partially through the rectangularopening, the rocker arm being movable between a first position and asecond position, wherein when the rocker arm is moved to the firstposition the rocker arm stays in the first position until the rocker armis moved to the second position and when rocker arm is moved to thesecond position the rocker arm stays in the second position until therocker arm is moved to the first position; and a membrane providedwithin the open interior area and adjacent the rocker arm, the membraneproviding a weatherproof seal between the rectangular opening and theopen interior area.
 2. The weatherproof switch cover of claim 1, whereinthe rocker arm comprises fingers that press into nubs provided in themembrane.
 3. The weatherproof switch cover of claim 2, wherein the nubscan press against a rocker arm of a decorator electrical switch.
 4. Theweatherproof switch cover of claim 1, further comprising a feedbackmechanism providing tactile feedback to a user when the rocker arm ismoved between the first and second positions.
 5. The weatherproof switchcover of claim 4, wherein the feedback mechanism comprises a springbiased finger movably provided in a center channel of the rocker arm. 6.The weatherproof switch cover of claim 5, wherein the feedback mechanismfurther comprises a flipper rockably provided on a pivot point, whereinthe spring biased finger rests on the flipper.
 7. A weatherproofelectrical kit comprising: a weatherproof electrical box; and aweatherproof switch cover mountable to the weatherproof electrical box,the weatherproof switch cover comprising: a base plate including top andbottom walls, a pair of side walls, an exterior surface and an openinterior area, the exterior surface being secured to or integrallymolded into the top and bottom walls and the pair of side walls, theexterior surface having at least one rectangular opening configured toalign with a decorator electrical switch and at least one hole forattaching the base plate to a yoke of the decorator electrical switch;at least one rocker arm operatively coupled to the base plate within theopen interior area and extending at least partially through the at leastone rectangular opening, the rocker arm being movable between a firstposition and a second position, wherein when the rocker arm is moved tothe first position the rocker arm stays in the first position until therocker arm is moved to the second position and when rocker arm is movedto the second position the rocker arm stays in the second position untilthe rocker arm is moved to the first position; and at least one membraneprovided within the open interior area and adjacent the at least onerocker arm, the membrane providing a weatherproof seal between the atleast one rectangular opening and the open interior area.
 8. Theweatherproof electrical kit of claim 7, wherein the rocker arm comprisesfingers that press into nubs provided in the membrane.
 9. Theweatherproof electrical kit of claim 8, wherein the nubs can pressagainst a rocker arm of a rocker style switch.
 10. The weatherproofelectrical kit of claim 8, wherein the weatherproof switch cover furthercomprises a feedback mechanism providing tactile feedback to a user whenthe rocker arm is moved between the first and second positions.
 11. Theweatherproof electrical kit of claim 10, wherein the feedback mechanismcomprises a spring biased finger movably provided in a center channel ofthe rocker arm.
 12. The weatherproof electrical kit of claim 11, whereinthe feedback mechanism further comprises a flipper rockably provided ona pivot point, wherein the spring biased finger rests on the flipper.13. The weatherproof electrical kit of claim 7 further comprising atleast one decorator electrical switch mountable to the weatherproofelectrical box and adapted for switching electrical power on and off.14. The weatherproof electrical kit of claim 7, wherein the weatherproofelectrical box comprises a single gang weatherproof electrical box. 15.The weatherproof electrical kit of claim 7, wherein the weatherproofelectrical box comprises a multi-gang weatherproof electrical box. 16.The weatherproof electrical kit of claim 7, wherein the weatherproofswitch cover comprises a single gang weatherproof switch cover.
 17. Theweatherproof electrical kit of claim 7, wherein the weatherproof switchcover comprises a multi-gang weatherproof switch cover.
 18. Aweatherproof multi-gang cover comprising: a base plate including top andbottom walls, a pair of side walls, an exterior surface and an openinterior area, the exterior surface being secured to or integrallymolded into the top and bottom walls and the pair of side walls, theexterior surface having at least two rectangular openings eachconfigured to align with a decorator electrical switch, and at least onehole for attaching the base plate to a yoke of at least one of thedecorator electrical switches; at least two rocker arms operativelycoupled to the base plate within the open interior area, wherein one ofthe at least two rocker arms extends at least partially through one ofthe at least two rectangular openings, each rocker arm being movablebetween a first position and a second position, wherein when each rockerarm is moved to the first position the rocker arm stays in the firstposition until the rocker arm is moved to the second position and whenthe rocker arm is moved to the second position the rocker arm stays inthe second position until the rocker arm is moved to the first position;and at least one membrane provided within the open interior area andadjacent the at least two rocker arms, the membrane providing aweatherproof seal between the at least two rectangular openings and theopen interior area.
 19. The weatherproof multi-gang cover of claim 18,wherein each rocker arm comprises fingers that press into nubs providedin the membrane.
 20. The weatherproof multi-gang cover of claim 19,wherein the nubs can press against a rocker arm of a rocker styleswitch.
 21. The weatherproof multi-gang cover of claim 18, furthercomprising a feedback mechanism providing tactile feedback to a userwhen each rocker arm is moved between the first and second positions.22. The weatherproof multi-gang cover of claim 21, wherein the feedbackmechanism comprises a spring biased finger movably provided in a centerchannel of the rocker arm.
 23. The weatherproof multi-gang cover ofclaim 22, wherein the feedback mechanism further comprises a flipperrockably provided on a pivot point, wherein the spring biased fingerrests on the flipper.
 24. A weatherproof multi-gang cover comprising: abase plate capable of being mounted to a yoke of a decorator electricalswitch and a yoke of a decorator receptacle, the base plate includes topand bottom walls, a pair of side walls, an exterior surface and an openinterior area, the exterior surface being secured to or integrallymolded into the top and bottom walls and the pair of side walls, theexterior surface having at least two rectangular openings; a rocker armoperatively coupled to the base plate within the open interior area andextending at least partially through a first of the at least tworectangular openings, the rocker arm being movable between a firstposition and a second position; a cover pivotally mounted to theexterior surface of the base plate and providing a weatherproof sealbetween a second of the at least two rectangular openings and the openinterior area when the cover is in a closed position; and a membraneprovided below the rocker arm, the membrane providing a weatherproofseal between the first rectangular opening and the open interior area.